EP0637605A1 - Process for forming polyurethane foam using mechanical cooling and an additive - Google Patents

Process for forming polyurethane foam using mechanical cooling and an additive Download PDF

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Publication number
EP0637605A1
EP0637605A1 EP94112138A EP94112138A EP0637605A1 EP 0637605 A1 EP0637605 A1 EP 0637605A1 EP 94112138 A EP94112138 A EP 94112138A EP 94112138 A EP94112138 A EP 94112138A EP 0637605 A1 EP0637605 A1 EP 0637605A1
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EP
European Patent Office
Prior art keywords
foam
process according
polyurethane foam
polyurethane
crosslinking
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
EP94112138A
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German (de)
English (en)
French (fr)
Inventor
Brian Hilker
Richard Gerkin
Greg Pickrell
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OSI Specialties Inc
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OSI Specialties Inc
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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08Processes
    • C08G18/16Catalysts
    • C08G18/18Catalysts containing secondary or tertiary amines or salts thereof
    • C08G18/1808Catalysts containing secondary or tertiary amines or salts thereof having alkylene polyamine groups
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08Processes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34Auxiliary operations
    • B29C44/56After-treatment of articles, e.g. for altering the shape
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08Processes
    • C08G18/16Catalysts
    • C08G18/18Catalysts containing secondary or tertiary amines or salts thereof
    • C08G18/1816Catalysts containing secondary or tertiary amines or salts thereof having carbocyclic groups
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08Processes
    • C08G18/16Catalysts
    • C08G18/18Catalysts containing secondary or tertiary amines or salts thereof
    • C08G18/20Heterocyclic amines; Salts thereof
    • C08G18/2009Heterocyclic amines; Salts thereof containing one heterocyclic ring
    • C08G18/2036Heterocyclic amines; Salts thereof containing one heterocyclic ring having at least three nitrogen atoms in the ring
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/04Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/12Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
    • C08J9/14Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent organic
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/22After-treatment of expandable particles; Forming foamed products

Definitions

  • the index number is the amount of isocyanate present in the foam as a percentage of the calculated stoichiometric amount of isocyanate needed to react all active hydrogen components m the formulation.
  • an isocyanate index of 110 means that 110% of the amount of isocyanate stoichiometrically required to react with all active hydrogen compounds is used.
  • Low index technologies use less than 100% of the amount of isocyanate needed to react all active hydrogen components in the formulation.
  • Low index technologies allow for lower exotherms and lower hardness values relative to conventional index all water based (i.e. , indexes typically greater or equal to 100) systems.
  • a lower index yields lower heat evolution due to lower isocyanate concentration and consequently yields lessened temperature related scorch and discoloration problems.
  • these lower index systems traditionally have been plagued by splitting problems, i.e. , sizeable openings or voids in either or both the surface and/or interior of the foams indicating a general lack of foam polymer network integrity.
  • such low index chemistries have been beset with poor physical properties including unacceptably high compression sets and foam integrity ( e.g. , crumbling) particularly in the foam centers.
  • Such problems have for the most part limited the use of these low index technologies to indexes above about 96 index, despite the use of some property enhancing additives.
  • U.S. Patent No. 4,970,243 to Jacobs discloses a process for producing flexible slabstock polyurethane foam comprising reacting one or more polyisocyanates with a compound containing at least two isocyanate-reactive hydrogen atoms and having a molecular weight of about 400 to about 10,000 grams/mole in the presence of water.
  • this patent does not disclose the use of additives so the compression sets (ASTM D-3574) are relatively high, greater than 20%.
  • Hager discloses a process for producing polyurethane foams which comprises reacting a mixture comprising polyether polyol, water, an organic polyisocyanate, a polyurethane foam catalyst and a foam processing aid which may include a cell opener.
  • the polyether polyol has an equivalent weight of between 500 to 1300.
  • the foam processing aid contains a crosslinking/extending agent which may be similar in structure to the polyol, but has an equivalent weight of less than 200 and may contain a cell opening agent which is a polyethylene oxide monol and/or polyol with an equivalent weight from about 200 to 5,000.
  • These foams must be allowed to cool in ambient air for at least 16 hours and have been known to have unacceptably high compression sets.
  • Such mechanical cooling systems typically require foam buns to be cured from 5 minutes to 4 hours (with the average being 10-30 minutes) after full-rise prior to cooling via blowing or vacuuming air through the foam.
  • This air treatment may contain one or more reactive species (water, amines, etc.) and be near or below room temperature.
  • the foams are significantly cooler and rendered virtually non-reactive after completion of these cooling/treatment processes as is evidenced by little or no Indentation Force Deflection (IFD) (ASTM D-3574) increase over time after cooling is completed.
  • IFD Indentation Force Deflection
  • Such processes allow for production schedules to be more "just-in-time" in nature than when using conventional non-cooling production methods. In addition, such processes allow faster overall production of foam.
  • Mechanical cooling is differentiated from chemical cooling in that an exterior fluid stream, i.e. , a gas, is applied to the solidified or gelled foam after rising, rather than the liquid foam containing a blowing agent.
  • a blowing agent cools mainly by heat of evaporation, but also expands the foam, decreasing the foam density.
  • the solvating nature of the blowing agents affect the foam morphology leading to softer than expected foam.
  • U.S. Patent 3,890,414 issued to Ricciardi discusses a process for improving the uniformity of the properties of a bun of polyurethane foam by rapidly and uniformly cooling a bun of hot freshly polymerized foam by passing a large quantity of a cooling gas through the foam mass.
  • U.S. Patent 5,128,379 to Stone discusses a process for rapidly cooling hot freshly polymerized foam by passing a fluid coolant stream having a water vapor content which initially is in the range from slightly below to above the dew point. But since the curing profile of foams produced using these cooling systems is significantly different than conventionally cured systems, many of the traditional physical property drawbacks common to high water foaming still remain with such a process.
  • U.S. Patent No. 5,171,756 to Ricciardi discloses the use of a three step vacuum method to cool, dehumidify, and remove fumes from freshly cured buns to prevent oxidation and auto-oxidation.
  • the polyurethane formulation comprises a polyether polyurethane, an organic diisocyanate, water and at least one softening agent.
  • the formulations often contain auxiliary blowing agents.
  • a preferred formulation is achieved by utilizing a mixture of two different polyols, a basic polyol having a molecular weight of 2500 to 4000 with a soft polyol with a molecular weight of about 1200 to about 1800.
  • the hydroxyl number of the basic polyol is between about 30 to 80, while the hydroxyl number of the soft polyol is between about 90 and 150.
  • This invention describes a method for making flexible, conventional, polyurethane slabstock foam having a substantially open cell structure from a polyfunctional polyol of 400-1500 equivalent weight, water, isocyanate, polyurethane catalysts and a foam processing aid which are combined and then mechanically cooled.
  • the foam processing aid contains at least one polyfunctional crosslinking agent which has at least two isocyanate reactive functionalities thereon and optionally contains a cell opening agent.
  • the present invention is based on the applicants' findings that small amounts of foam additives in conventional all water blown polyurethane slabstock foam formulations which are subjected to mechanical cooling processes shortly after blow-off yield split free, open cell structured foam with acceptable physical properties, particularly compression sets.
  • the area of polyurethane technology to which this invention relates is that of polyurethanes with moderate resiliency and moderate to high IFD Return Percentages (ASTM D-3574).
  • the present invention shows enhanced compression set performance for polyurethanes using this additive technology combined with mechanical cooling.
  • the present invention eliminates a key problem of all prior water blown, low density, soft polyurethane foam formulations employing mechanical cooling methods.
  • the polyurethane slabstock foam contemplated herein is comprised of (I) one or more polyols; (II) one or more organic isocyanates; (III) blowing agents; (IV) one or more surface active agents; (V) one or more catalysts; (VI) one or more foam processing aids; and optionally, one or more of (VII) other standard ingredients known to those skilled in the art.
  • a similar formulation of polyurethane foam has been previously disclosed in Hager, which is incorporated herein by reference. To follow is a description of each component of the invention.
  • the polyols, Group (I), which can be utilized in the present invention include, but are not limited to, the following polyether polyols: (a) alkylene oxide adducts of polyhydroxyalkanes; (b) alkylene oxide adducts of non-reducing sugars and sugar derivatives; (c) alkylene oxide adducts of polyphenols; and (d) alkylene oxide adducts of polyamines and polyhydroxyamines.
  • Alkylene oxides having two to four carbon atoms generally are employed, with propylene oxide, ethylene oxide and mixtures thereof being particularly preferred.
  • Any material having active hydrogens may be utilized to some extent and therefore is included within the broad definition of the polyols of Group(I).
  • amine-terminated polyether polyols, hydroxyl-terminated polybutadiene polyols and many others are known and may be used as a minor component in combination with the above-identified conventional polyether polyols.
  • the polyol compound (I) should have an equivalent weight in the range of about 400 to about 1500 grams/equivalent and an ethylene oxide content of less than 20%.
  • the equivalent weight is in the range of about 500 to about 1300 grams/equivalent, and most preferably between about 750 and 1250 grams/equivalent.
  • the polyol or polyol blend should have an average hydroxy functionality of at least 2. The equivalent weight is determined from the measured hydroxyl number. The hydroxyl number is defined as the number of milligrains of potassium hydroxide required for the complete hydrolysis of the fully acetylated derivative prepared from one gram of polyol.
  • polyols have hydroxyl numbers preferably in the range of about 43 to about 110, and more preferably in the range of about 45 to about 75.
  • the polyols should include the poly(oxypropylene) and poly(oxyethyleneoxypropylene) triols.
  • Ethylene oxide when used, can be incorporated in any fashion along the polymer chain. Stated another way, the ethylene oxide can be incorporated either in internal blocks, as terminal blocks, or may be randomly distributed along the polyol chain.
  • the manner of incorporation and the ethylene oxide content of the polyol preferably is as noted above.
  • ethylene oxide is used at a level below about 20% by weight, preferably below about 15% by weight, and is located primarily within the interior of the polyol chain.
  • a portion or all of the polyol component may be added in the form of a polyol polymer in which reactive monomers have been polymerized within a polyol to form a stable dispersion of the polymer solids within the polyol.
  • the amount of polyol used is determined by the amount of product to be produced. Such amounts may be readily determined by one skilled in the art.
  • Organic isocyanates (Group II) useful in producing polyurethane foam in accordance with this invention are organic compounds that contain, on average, between about one and a half and about six isocyanate groups, and preferably about two isocyanate groups.
  • Suitable organic polyisocyanates include the hydrocarbon diisocyanates, e.g. , the alkylene diisocyanates and the aryl diisocyanates and more specifically, diphenylmethane diisocyanate and toluene diisocyanate ("TDI").
  • Preferred polyisocyanates are 2, 4 and 2, 6 toluene diisocyanates and their mixtures having a functionality of about 2, which are broadly referred to herein simply as TDI.
  • the most preferred polyisocyanate is 80/20 TDI ( i.e. , a mixture of 80% 2,4-toluene diisocyanate and 20% 2,6-toluene diisocyanate).
  • the amount of isocyanate to be used is dependent upon the index of foam desired and the final properties of the foam to be formed. As stated above, if the index is 100, then there is a stoichiometric equivalent of the amount of isocyanate needed to react with the polyol component (Group I) and the other active hydrogen containing components in the system. While the present invention may be practiced in a wide range of indexes, the preferred range of use is indexes between 95 and 115 (hereinafter "High Index").
  • the low index formulation taught by Hager 60-95, hereinafter “Low Index”
  • Low Index Low Index
  • Water (Component III) is preferably the sole blowing agent to produce carbon dioxide by reaction with isocyanate. Water should be used at about 1 to 12 pphp (parts per hundred of polyol (Group I)) and preferably between 2 and 10 pphp. At foam indexes below 100, the stoichiometric excess of water cools and blows via vaporization, not as part of the reaction to produce carbon dioxide.
  • Other blowing agents that are conventionally used in the art may be used herein, but because of the utility of the formulation of the present invention, large amounts of such agents are no longer needed and in many cases none are needed at all.
  • Suitable stabilizers (Group IV) for slabstock applications include "hydrolyzable” polysiloxane-polyoxyalkylene block copolymers.
  • Another useful class of foam stabilizers are the "non-hydrolyzable” polysiloxane-polyoxyalkylene block copolymers.
  • the latter class of copolymers differs from the above-mentioned polysiloxane-polyoxyalkylene block copolymers in that the polysiloxane moiety is bonded to the polyoxyalkylene moiety through direct carbon-to-silicon bonds, rather than through carbon-to-oxygen-to-silicon bonds.
  • Most preferred are the silicone surfactants L-620 and L-603 available from OSi Specialties, Inc. of Danbury, CT.
  • the stabilizer should be present at about 0.0001 percent to about 5 percent by weight of the total reaction mixture.
  • Component (V) includes the standard combination of tertiary amine and organometallic polyurethane catalysts which should be present at about 0.0001 to 5 weight percent of the reaction mixture.
  • Suitable catalysts include, but are not limited to, dialkyltin salts of carboxylic acid, tin salts of organic acids, triethylene diamine (TEDA), bis (2,2'-dimethylaminoethyl) ether and similar compounds that are known to the art.
  • a foam processing aid (Group VI) is used for enhancing the properties of low density, slabstock foam, said foam processing aid includes a crosslinking agent and/or extending agent and preferably a sufficient amount of a cell opening agent, to yield a polyurethane foam having a porosity greater than about 40 cubic feet per minute per square foot (CFM-ft2).
  • a relatively low molecular weight (generally below about 250 gms/mole) polyfunctional glycol crosslinking/extending agent is preferred to make stable, free-rise foams.
  • the equivalent weights of these agents are generally less than about 200, but in certain circumstances they may be higher.
  • the reactive group functionality of these compounds should be at least two, and preferably in a mixture of agents, at least one has a functionality of three or greater.
  • the inventors have found that such polyfunctional isocyanate reactive compounds, such as a hexahydroxy functional alkane of a molecular weight of approximately 182 gms/mole with an equivalent weight of 30, are preferred. The inventors believe that this is so because higher functional compounds build polymer structure more readily than the lower functionality components.
  • the polyols that are of use herein, unlike those previously described, may include primary polyols.
  • the crosslinking/extending agent should be present between about 0.1 and 10 pphp and preferably, between 0.2 and 5 pphp. Because polyfunctional isocyanate reactive compounds are being used herein, the amount of crosslinking/extending agent is lessened as compared to the teachings of Hager.
  • polyfunctional isocyanate reactive components which have not been previously known for use as additives in forming polyurethane foam, may be used with the present invention.
  • these include, other high molecular weight cross-linking agents that are polyvinyl alcohol homo- and copolymers of numerous monomers, including polyvinyl butyral, which has a molecular weight of 2,000-20,000, hydroxyethyl(meth)acrylate homo- and copolymers of molecular weight 2,000-20,000, hydroxyl derivatives of polyvinyl ethers such as hydroxybutyl vinyl ether homo- and co-polymers of molecular weight 2,000-20,000 and similar polymers.
  • These polymers may have equivalent weights greater than 200 which may be preferred in certain usages. Generally, the equivalent weight is between 50 and than 2,000. Moreover, the molecular weight of these polymers are from 2,000 to 20,000.
  • the cell opening agent is preferably a polyethylene oxide monol or polyol of an equivalent weight greater than 200, with 200-1,000 being preferable, with a hydroxyl functionality of two or greater.
  • one of the preferred cell opening agents is a polyethylene oxide adduct of glycerol of a molecular weight of about 990 gms/mole, with an equivalent weight of about 330.
  • the cell opening agent should be present at about 0 to 20 pphp. Note that in certain cases, despite the equivalent weight difference, the cell opener may act as a crosslinking agent and vice-versa, thereby reducing the need for the crosslinking agent or cell opening agent, as the case may be.
  • the weight ratio of the cell opening agent to crosslinking agent present in the composition should be about 6:1 to 1:2, with 3:1 being the preferable ratio.
  • the inventors have found that combinations of cell opening agent and crosslinking agent within this preferred range have a symbiotic effect on the foam. For example, when a cross-linking agent was used alone, foams were stable with no splits, but were tight with low air flow resulting in poor compression sets. If a cell opening agent is used alone the foam will be very open with center splits and possessed moderate compression sets at best. In the preferred range of ratios, combinations lead to spilt-free, stable open foams with low compression sets.
  • Solid stabilizing polymers (VII) and other additives, including flame retardants, colorants, dyes and anti-static agents, which are conventionally known in the art may be used with the formulations of the present invention.
  • flame retardants including flame retardants, colorants, dyes and anti-static agents
  • Those listed in U.S. Patent No. 4,950,694 are exemplary and are incorporated herein.
  • the required amount of toluene diisocyanate is calculated from the amount of polyol, water, foam processing aid and the desired index.
  • the polyol, surfactant, amine, additive, water and other additives are mixed together and agitated. During such agitation, the organometallic catalyst and the isocyanate are added and mixing continues until homogeneous.
  • the mixing stops the liquid foam mass is poured as quickly as possible into the desired form. After gas release starts occurring the foam is to be mechanically cooled.
  • the mechanical cooling is intended to decrease the temperature of the foam, which may be higher than about 400°F, to temperatures below about 250°F to about 200°F, below the oxidation danger zone, and indeed may be used to cool the foam all the way down to room temperature.
  • Both fluid and gaseous cooling streams can be used by either applying the cooling stream to the foam block, or passing the foam block through an apparatus containing the cooling stream.
  • Such processes include cutting slits in the surface of the foam, removing the skin of the foam thereby opening the foam and punching holes through the foam.
  • Such mechanical cooling may be present in the manufacturing process as either an in-line process or a post-production process. Exemplary methods are described in U.S. Patent No. 4,537,912 issued to Griswold, U.S. Patent No. 5,128,379 issued to Stone, U.S. Patent No. 5,188,792 to Drye et al. and U.S. Patent No.
  • the desired amount of TDI was calculated given the desired index and the hydroxyl group number of the polyol to be used.
  • a Milltronics Microranger Ultrasonic level Measuring Instrument (Sonar Unit) was calibrated so that it could be used to measure how fast the foam rises, i.e. , height as a function of time.
  • a syringe for dispensing the tin catalyst was also calibrated, and the desired amount of tin catalyst was loaded into the syringe. The proper amount of TDI was weighed into a beaker.
  • glycerin 100 grams of a glycerin started, 56 hydroxyl number polyoxypropylene terminated polyoxyethlene polyoxypropylene polyol, 1.0 grams of silicone surfactant L-620 from OSi Specialties, Inc., 0.22 grams of amine catalyst C-183 from OSi Specialties, Inc., 5.0 grams of an additive, and 5.25 grains of distilled water were weighed into a paper mixing cup.
  • the additive was about 56% 500 molecular weight polyoxyethylene adduct of glycerin, 19% sorbitol, and 25% distilled water.
  • the contents of the mixing cup were thoroughly agitated for 60 seconds using the drill press based blade mixing system at 2500 RPM attached to the pre-programmed timer.
  • the drill press was stopped for 15 seconds after initial mixing (according to the pre-programmed schedule) in which time 0.09 grains of tin catalyst T-9 from Air Products Co. of Allentown, PA was added via syringe.
  • the drill press was restarted and mixed for 9 more seconds.
  • 64.38 grains of TDI were added in one quick addition with continued and additional mixing for 6 seconds.
  • the liquid foam mass was poured as quickly as possible into a 12x12x16 inch cardboard box which was lined with a polyethylene trash bag (less than about 5 seconds). The gas release was recognized as bubbles appearing at the surface of the foam.
  • 5-6 holes (2-3 mm diameter, 6 cm deep) were punched through the skin of the foam on the bottom of the foam to allow air movement through the bun. These holes were placed closely together so that the vacuum hose could cover all of them. In addition, 5-6 holes (2-3 mm diameter, 6 cm deep) were punched equidistantly throughout the skin of the top of the foam.
  • the hose of the Sears Craftsman Wet/Dry Vac (8 gallon 2.25 HP) was placed on the bottom of the foam over the holes previously punched and air pulled through the foam for 2 minutes at full vacuum power.
  • a Sonar Unit was set to take data for up to 5 minutes after initial mixing. This sonar unit was removed prior to vacuum cooling. The final exotherm was recorded using a quick response digital thermometer. Finally, the foam was left inside the hood for 24 hours and thereafter was cut and its physical properties were evaluated.
  • 5-6 holes (approximately 2-3 mm diameter and 5-7 cm deep) were punched through the skin of the foam on the bottom of the foam to allow air movement through the bun. These holes were placed so that the vacuum hose could cover all of them. In addition, 5-6 holes (2-3 mm diameter and 5-7 cm deep) were punched equidistantly throughout the skin of the top of the foam. A vacuum hose was placed on the bottom of the foam over the holes previously punched and air was sucked through the foam.
  • the index number of the foam treated with both the additive and the mechanical cooling process was significantly lower than the index number for the foam treated only with the mechanical cooling process.
  • the IFD values (ASTM D-3574) and compression sets (ASTM D-3574) of the foam treated with both the additive and mechanical cooling process were significantly lower.
  • the percent return of the foam treated with both the additive and the mechanical cooling process was much higher than the foam treated with the mechanical cooling process alone.
  • Example 2 was mechanically cooled per U.S. Patent No. 5,171,756, while Comparative Example 2 was not.
  • the resulting physical characteristics of the foams are also set forth below. Surprisingly, the cooling of a Low-Index foam composition with an additive did not result in an inferior product, but rather showed some improvement in some physical characteristics.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Polyurethanes Or Polyureas (AREA)
EP94112138A 1993-08-03 1994-08-03 Process for forming polyurethane foam using mechanical cooling and an additive Ceased EP0637605A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US101189 1987-09-25
US10118993A 1993-08-03 1993-08-03

Publications (1)

Publication Number Publication Date
EP0637605A1 true EP0637605A1 (en) 1995-02-08

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EP94112138A Ceased EP0637605A1 (en) 1993-08-03 1994-08-03 Process for forming polyurethane foam using mechanical cooling and an additive

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US (1) US5539011A (ja)
EP (1) EP0637605A1 (ja)
JP (1) JPH07165863A (ja)
KR (1) KR950005865A (ja)
AU (1) AU6886494A (ja)
BR (1) BR9403138A (ja)
CA (1) CA2129417A1 (ja)
ZA (1) ZA945718B (ja)

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US8372912B2 (en) * 2005-08-12 2013-02-12 Eastman Chemical Company Polyvinyl chloride compositions
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KR950005865A (ko) 1995-03-20
US5539011A (en) 1996-07-23
AU6886494A (en) 1995-02-16
CA2129417A1 (en) 1995-02-04
BR9403138A (pt) 1995-04-11
ZA945718B (en) 1995-03-09

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